Heat-dissipating bedding product

ABSTRACT

The present invention relates to bedding product having heat-dissipation and support properties provided by structural protrusions on the surface of the bedding product. The bedding product may comprise a first layer of foam, that includes a base support having an upper surface and a lower surface and a plurality of open and closed protrusions located on the upper surface of the base support. Each open protrusion comprises a cavity formed therein, wherein the cavity has a depth of at least 0.5 inch

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to U.S. ProvisionalPatent Appl. No. 63/181,605 filed Apr. 29, 2021, the disclosure of whichis hereby incorporated by reference in its entirety.

FIELD

The present disclosure generally relates to a bedding product havingheat-dissipation and support properties provided by structuralprotrusions on the surface of the bedding product.

BACKGROUND

Mattress manufacturers have made significant improvements in mattresscomfort in recent decades. Some such improvements arose from theintroduction of foams (e.g., polyurethane foam) and layering structureswithin the mattresses.

Foams have numerous characteristics, including density and firmness,that contribute to the “feel” of the mattress. Density generally refersto the amount of gas-containing cells within a foam matrix. Firmnessgenerally refers to the rigidity of the matrix, such as polyurethane,itself. Varying the density and firmness of a foam can thus provide amattress having a different feel. Further, many different mattressespossessing a broad spectrum of feel may be produced by combining layersof different types of foams. Yet, while foam mattresses have achievedbroad acceptance for some improved aspects of comfort, some suchmattresses have exhibited negative performance issues related toinsufficient thermal comfort and support.

In general, conventional foams have a closed cell structure, whichrestricts air flow in the mattress and causes the foam to act as athermal insulator with poor heat transfer characteristics. As a result,consumers tend to find that foam mattresses cause the user to feel toohot while sleeping. Conventional foam mattresses are also found toprovide insufficient support to the individual laying on the mattress.This may be because many foams do not conform well to the curves of anindividual's body, and thus the individual's bodyweight is selectivelysupported at only a few points of the foam rather than along the entirelength of the foam adjacent to the individual's body. A related problemis often referred to as “bottoming out,” whereby the individual's weighton the foam compacts the foam to such a degree that resilience is lost.Typical foams bottom out and exhibit a hard feel as they are compactedby the weight of an individual's body.

Given the foregoing, there is a need for improved mattresses thatprovide greater thermal comfort and overall support.

SUMMARY

In one aspect, the disclosed technology relates to a bedding productincluding a first layer of foam, wherein the first layer includes: abase support having an upper surface and a lower surface; a plurality ofopen protrusions positioned on the upper surface of the base support,each open protrusion including a cavity formed therein, wherein thecavity has a depth of at least 0.5 inch; and a plurality of closedprotrusions positioned on the upper surface of the base support. In someembodiments, the cavity of the open protrusion has a depth of at least 1inch. In some embodiments, the open and closed protrusions are arrangedin a pattern along the upper surface of the base support. In someembodiments, the open protrusions are arranged in one or more heat-sinkgroupings; the closed protrusions are arranged in one or more supportgroupings, and the heat-sink groupings and the support groupings arearranged in an alternating pattern. In some embodiments, at least one ofthe heat-sink grouping includes five or more open protrusions, and atleast one of the support grouping includes five or more closedprotrusions. In some embodiments, at least one of the support groupingsforms a support zone positioned to correspond to a predetermined portionof a user's body and to provide resistance that promotes at least oneeffect on the user's body selected from blood circulation, recovery, andfacilitation of slow wave sleep.

In some embodiments, the first layer defines an uppermost foam layer ofthe bedding product. In some embodiments, the bedding product includes aplurality of layers and the first layer is the uppermost support layer.In some embodiments, top surfaces of the open and closed protrusionsdefine an uppermost foam surface of the bedding product. In someembodiments, at least one closed protrusion has a continuous topsurface. In some embodiments, at least one closed protrusion is solid.In some embodiments, a top surface of at least one closed protrusion isoutwardly rounded.

In some embodiments, the bedding product further includes a second layerdirectly attached to the lower surface of the base support. In someembodiments, the second layer is the same as the first layer. In someembodiments, the base support has a thickness of about 0.25 inches toabout 3 inches. In some embodiments, the bedding product is a mattress.In some embodiments, the bedding product is a mattress topper.

In some embodiments, the bedding product provides greaterheat-dissipation than a bedding product including a base support withoutprotrusions. In some embodiments, the bedding product provides greaterair flow than a bedding product including a base support withoutprotrusions.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and constitutepart of this specification, are illustrative of particular embodimentsof the present disclosure and do not limit the scope of the presentdisclosure. The drawings are not to scale and are intended for use inconjunction with the explanations in the following detailed description.

FIG. 1A is a cross-sectional view of an embodiment of a heat-dissipatingbedding product disclosed herein, including heat-sink zones and supportzones.

FIG. 1B is an image showing the upper surface of an embodiment of aheat-dissipating bedding product disclosed herein.

FIG. 1C is a top view of a portion of an embodiment of aheat-dissipating bedding product disclosed herein.

FIG. 1D is an enlarged perspective cross-sectional view of protrusionsof an embodiment of a heat-dissipating bedding product disclosed herein.

FIG. 2A illustrates an example of a zoning pattern, including heat-sinkzones and support zones, of an embodiment of a heat-dissipating beddingproduct disclosed herein.

FIG. 2B illustrates another example of a zoning pattern, includingheat-sink zones and support zones, of an embodiment of aheat-dissipating bedding product disclosed herein.

FIG. 3 is a cross-sectional view of an embodiment of a multi-layerheat-dissipating bedding product disclosed herein.

FIG. 4 illustrates various zones of an embodiment of a heat-dissipatingbedding product disclosed herein, wherein the zones correspond toportions of an individual's body.

DETAILED DESCRIPTION

The following discussion omits or only briefly describes conventionalfeatures of the disclosed technology that are apparent to those skilledin the art. It is noted that various embodiments are described in detailwith reference to the drawings, in which like reference numeralsrepresent like parts and assemblies throughout the several views. Indrawings that depict multiple like components, a single representativecomponent may be identified by the appropriate reference numeral.Reference to various embodiments does not limit the scope of the claimsappended hereto. Additionally, any examples set forth in thisspecification are intended to be non-limiting and merely set forth someof the many possible embodiments for the appended claims. Further,particular features described herein can be used in combination withother described features in each of the various possible combinationsand permutations. Although any methods and materials similar orequivalent to those described herein can be used in the practice ortesting of embodiments of the present disclosure, selected methods,devices, and materials are now described.

Unless otherwise specifically defined herein, all terms are to be giventheir broadest possible interpretation including meanings implied fromthe specification as well as meanings understood by those skilled in theart and/or as defined in dictionaries, treatises, etc. It must also benoted that, as used in the specification and the appended claims, thesingular forms “a,” “an” and “the” include plural referents unlessotherwise specified, and that the terms “comprises” and/or “comprising,”when used in this specification, specify the presence of statedfeatures, elements, and/or components, but do not preclude the presenceor addition of one or more other features, steps, operations, elements,components, and/or groups thereof.

The present disclosure relates to a heat-dissipating bedding product 10having surface designs that provide greater thermal comfort and overallsupport. In some embodiments, the disclosed surface designs improve airflow and cooling while simultaneously providing better support when thebedding product is in use.

Bedding Product

As used herein, the term “bedding product” includes, without limitation,mattresses, pillows, mattress toppers, seat cushions, back and lumbarsupports, chair pads, benches and any product intended to support atleast part of a body—e.g., a body of a mammal, such as a human. Unlessotherwise stated, various dimensions of the bedding products disclosedherein are non-limiting and provided for illustrative purposes only.

FIGS. 1A-1D depict an illustrative embodiment of a heat-dissipatingbedding product 10, which includes a first layer 12 comprising: a basesupport 15 having an upper surface 14 and a lower surface 16, andprotrusions 18, 22 that extend upwards from the upper surface 14 of thebase support 15. As shown, the first layer 12 is the uppermost layer ofthe bedding product 10. In some embodiments, the first layer 12 is theuppermost support layer of the bedding product 10, which means it is theuppermost layer of the product that is configured to provide physicalsupport to the body of a user. In some embodiments, the first layer 12is the uppermost foam layer of the bedding product 10, which means thatit is the uppermost layer that comprises foam. In some embodiments, thebase support 15 has a thickness 50 of about 0.25 inch to about 3 inches,about 0.25 inch to about 2.5 inches, about 0.25 inch to about 2 inches,about 0.25 inch to about 1.5 inches, about 0.25 inch to about 1 inch,0.5 inch to about 3 inches, about 0.5 inch to about 2.5 inches, about0.5 inch to about 2 inches, about 0.5 inch to about 1.5 inches, or about0.5 inch to about 1 inch. In some embodiments, the base support 15 has athickness 50 in a first direction, and the open 18 and closed 22protrusions extend from the upper surface 14 of the base support 15 inthe first direction.

In the first layer 12, the plurality of protrusions 18, 22 that extendupwards from the upper surface 14 of the base support 15 are separatedby channels 32, as shown in FIGS. 1A-1D. In general, the protrusions maybe open 18 or closed 22. For example, a first type of protrusion may bean open protrusion 18 having a cavity 20 formed in its top surface 26that extends (e.g., curves) inward toward the base support 15. A secondtype of protrusion may be a closed protrusion 22 having a continuous,uninterrupted top surface 24. In some embodiments, the top surface 24 issubstantially flat, convex, or outwardly rounded. In some embodiments,top surfaces 24, 26 of protrusions 18, 22, respectively, provide theuppermost surface of the first layer 12. In some embodiments, topsurfaces 24, 26 of protrusions 18, 22, respectively, provide theuppermost foam surface of the bedding product 10.

In general, open protrusions 18 provide increased heat-dissipation andair flow within the bedding product 10 via cavities 20. In someembodiments, the open protrusions 18 are arranged in groupings to formheat-sink groupings or heat-sink zones 4 along upper surface 14 of basesupport 15. In some embodiments, a grouping includes a plurality of thesame type of protrusion e.g., a plurality of open protrusions 18 or aplurality of closed protrusions 22. In some embodiments, the beddingproduct 10 provides greater air flow and/or heat-dissipation than abedding product without protrusions 18, 22. In some embodiments, agrouping may include five or more open protrusions 18 and/or five ormore closed protrusions 22. In other embodiments, a grouping includes aplurality of different types of protrusions—i.e., some open 18 and someclosed 22. In some embodiments, a grouping of one type of protrusion ispositioned directly adjacent to a grouping of a different type ofprotrusion. In some embodiments, the groupings are configured in acertain arrangement, such as rows. In some embodiments, the groupingsare arranged in a pattern such as an alternating pattern.

In general, closed protrusions 22 provide the bedding product 10 withincreased support. In some embodiments, the closed protrusions 22 may besolid or hollow. In some embodiments, the closed protrusion 22 has acontinuous top surface 24. In other embodiments, the closed protrusion22 has a perforated top surface 24. In some embodiments, one or moreclosed protrusions 22 has a greater stiffness than one or more openprotrusions 18. In some embodiments, the closed protrusions 22 arearranged in groupings to form support groupings or support zones 2 alongupper surface 14 of base support 15. Support zones 2 may promote bloodcirculation, recovery, and/or facilitation of slow wave sleep.

The heat-sink zones 4 and support zones 2 may be arranged in a varietyof different patterns, as desired. Bedding product 10 may include aplurality of zones, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or morezones. In one non-limiting example, an embodiment comprising at leasttwo zones may have a plurality of rows (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9,10 or more rows) of open protrusions 18 (i.e., a grouping of openprotrusions 18) that form a heat-sink zone 4 positioned directlyadjacent a plurality of rows (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 ormore rows) of closed protrusions 22 (i.e., a grouping of closedprotrusions 22) that form a support zone 2, optionally in a repeatingpattern. In some embodiments, the pattern extends across more than 75%(e.g., more than 80%, more than 90%, or 100%) of the entire uppersurface 14 of base support 15. In some embodiments, the pattern mayinclude the same number of arrangements (e.g., rows) in each grouping,such as five arrangements of open protrusions 18 followed by fivearrangements of closed protrusions 22. In other embodiments, the patternmay include different numbers of arrangements (e.g., rows) in eachgrouping, such as: seven arrangements of open protrusions 18 followed bythree arrangements of closed protrusions 22; or three arrangements of acombination of open 18 and closed protrusions 22, followed by fourarrangements of open protrusions 18, followed by three arrangements ofclosed protrusions 22; or other desirable configurations. In someembodiments, the open 18 and closed 22 protrusions of the first layer 12may have a random or unorganized arrangement.

In some embodiments, the support zones 2 are positioned together inareas of the upper surface 14 of the base support 15 so as to directlysupport select parts of a user's body, such as the head, neck,shoulders, waist, hips, legs, feet, or any combination thereof. In someembodiments, one or more support zones 2 are arranged between heat-sinkzones 4 in order to provide increased heat-dissipation and comfort. Forexample, FIGS. 2A and 2B show support zones 2 positioned together on thesurface of the bedding product 10 so as to directly support the variousparts of a user's body. As shown in these figures, each support zone 2is formed by a plurality of rows of closed protrusions 22, with the morecentrally positioned support zones 2 arranged between heat-sink zones 4,each of which is formed by a plurality of rows of open protrusions 18.In some embodiments, closed protrusions 22 and open protrusions 18 maybe arranged together so as to provide both support and heat-dissipationwithin a single zone or region of the bedding product 10.

The embodiments described herein are not limited to this particularconfiguration of zones and divisions. Instead, a variety of zones andarrangements thereof is possible. The size of the zones shown in FIGS.2A and 2B may be determined using human anthropometric data. Forexample, a person may be selected as one of typical size and height fora human adult, or one representing a range of adult sizes and heights,such as adults ranging from 4′-10″ in size to 6′-10″ in height, 5′-0″ to6′-0″ in height, or any other suitable range. Non-limiting andrepresentative examples of the length of various zones is shown in FIG.4, but other dimensions are possible and contemplated by the presentdisclosure. As depicted in FIG. 4, bedding product 10 includes fivezones 40, 42, 44, 46, 48.

In some embodiments, the bedding product 10 may be a mattress ormattress topper that includes a plurality of zones, each of which isconfigured to correspond to (i.e., be positioned generally under) anarea of the body of a person who is lying on the bedding product 10. Forexample, such a mattress or mattress topper may include one or more ofthe following zones: head/neck 40, shoulders 42, waist 44, hips 46, andlegs/feet 48.

In some embodiments, the heat-dissipating bedding product 10 comprises asingle layer, such as a layer that is not structurally secured to otherlayers. In other embodiments, the heat-dissipating bedding product 10comprises a plurality of layers, wherein a first layer 12 isstructurally secured to one or more other layers (above and/or below thefirst layer 12) to form a multi-layer bedding product 10. In someembodiments of a multi-layer bedding product 10, two or more of thelayers are configured as described for first layer 12 and thus mayinclude both heat-sink 4 and support zones 2 to further improveheat-dissipation and comfort provided by the bedding product 10. Forexample, FIG. 3 depicts two layers of a bedding product 10, wherein eachlayer comprises a combination of open 18 and closed protrusions 22. Asshown in this figure, each layer provides a different zoning pattern,which may increase the depth of the heat-sinks 4 in some zones and thusmay increase heat-dissipation and comfort. In another embodiment, eachlayer may provide the same zoning pattern. In yet another embodiment, afirst layer 12 may be structurally secured to one or more other layers(above and/or below the first layer 12) that does not include heat-sinkzones 4 and/or support zones 2, or that includes fewer or more heat-sinkzones 4 and/or support zones 2. In some embodiments, lower layers mayprovide the bedding product 10 with additional performance enhancingproperties.

In some multi-layer embodiments, “structurally secured” refers to afirst layer 12 being affixed to an adjacent (i.e., overlying orunderlying) layer via an upper and/or lower surface 16 of the firstlayer 12. The first layer 12 may be affixed to the adjacent layer(s)continuously across more than 75% (e.g., more than 80%, more than 90%,or 100%) of the upper 14 and/or lower 16 surface of the first layer 12.In other embodiments, the first layer 12 is affixed to the adjacentlayer(s) in a different manner—e.g., non-continuous, along an interiorperiphery between the layers, along the edges of the layers, etc. Insome embodiments, more than 75% (e.g., more than 80%, more than 90%, or100%) of the top surfaces of the open and closed protrusions 24, 26 offirst layer 12 may be structurally secured to the lower surface 16 of anoverlying layer. In some multi-layer embodiments, the first layer 12 maybe the uppermost support layer.

Layers of bedding product 10 may be affixed to each other by anysuitable means known in the art. For example, layers may be sprayed-on,injection molded, extruded, coextruded, laminated, stapled, tacked,welded, laminated, mechanically affixed via friction or interferencefit, adhered via one or more of an adhesive, a glue, a cement, or othermaterial with adhesive properties, stitched, affixed via hook and loopfastener, a Zipper, a Dennison-style tag, snaps, and/or other reversiblemeans, and combinations thereof.

Non-limiting examples of suitable adhesives include hot melt,water-based, and pressure-sensitive adhesives, fire-resistant adhesives,mixtures thereof, and other suitable adherent materials or fastenersknown in the art. Suitable hot melt adhesives include those availablefrom Henkel (Rocky Hill, Conn.) and UPACO brand adhesives available fromWorthen Industries (Nashua, N.H.). Suitable water-based adhesivesinclude water-based adhesives under the SIMALFA brand available fromAlfa Adhesives, Inc. (Hawthorne, N.J.). In some embodiments, a layer mayfurther include a silica, a metallic layer, a plastic, such as anacrylic, a modacrylic, a polyolefin, a latex, a polyurethane, andcombinations and/or blends thereof.

In some embodiments, each layer may further include one or morebiocides, preservatives, odor blocking agents, scents, pigments, dyes,stain guards, antistatic agents, anti-soiling agents, water-proofingagents, moisture wicking agents, and combinations thereof.

One or more lower layers may be of any thickness suitable for a beddingproduct. For example, one or more lower layers may have a thickness ofabout 12 inches or less, such as about 10 inches or less, about 8 inchesor less, about 6 inches or less, about 4 inches or less, about 2 inchesor less, about 1 inch or less, about 0.5 inch or less.

One or more lower layers may comprise one or more materials selectedfrom fabric, natural fiber, synthetic fiber, a ticking layer, a quiltlayer, a thread layer, a film, a foam, a gel, a gel foam, a multi gelfoam, a high thermal conductivity foam, a woven layer, a nonwoven layer,a fire-resistant layer, a non-skid layer, and combinations thereof. Insome embodiments, the bedding product 10 includes a component corelayer, which may comprise any suitable mattress core constructionmaterial such as, but not limited to, foam core, gel foam core, latexcore, an inner spring layer, a layer of individually wrapped coils, aninflated air system, a liquid system (e.g., water), or a combinationthereof.

In some embodiments, the bedding product 10 may be a final product,inclusive of all layers, having a thickness of about 0.25 inch to about25 inches, such as about 1 inch to about 25 inches, about 2 inches toabout 25 inches, about 3 inches to about 25 inches, about 4 inches toabout 25 inches, about 5 inches to about 25 inches, about 1 inch toabout 20 inches, about 2 inches to about 20 inches, about 3 inches toabout 20 inches, about 4 inches to about 20 inches, or about 5 inches toabout 20 inches.

Open/Closed Protrusions

As described above, the bedding product 10 may include protrusions 18,22 positioned on the upper surface 14 of the base support 15. Theprotrusions 18, 22 may be directly attached to the base support 15(e.g., integrally formed as a single piece) or may be separate and/ordetachable from the base support 15. In some embodiments, the basesupport 15 and protrusions 18, 22 are formed from the same material.Methods of manufacturing the bedding product 10, including the basesupport 15 and protrusions 18, 22, are described in below.

The dimensions and shapes of open protrusions 18 and closed protrusions22 may vary. For example, as illustrated in FIG. 1D, the height 52 of aclosed protrusion 22 may be greater than the height 52 of an openprotrusion 18, wherein the height 52 is measured from the upper surface14 of the base support 15 to the highest portion of the protrusion.Alternatively, the height 52 of a closed protrusion 22 may be the sameas or less than the height 52 of an open protrusion 18. Non-limitingexamples of suitable heights 52 for an open protrusion 18, closedprotrusion 22, or both include: about 0.25 inch to about 2 inches, about0.25 inch to about 1.75 inches, about 0.25 inch to about 1.5 inches,about 0.25 inch to about 1.25 inches, about 0.25 inch to about 1.0 inch,about 0.25 inch to about 0.75 inch, about 0.5 inch to about 2 inches,about 0.5 inch to about 1.75 inches, about 0.5 inch to about 1.5 inches,about 0.5 inch to about 1.25 inches, about 0.5 inch to about 1.0 inch,and about 0.5 inch to about 0.75 inch.

As illustrated in FIG. 1D, the width (or diameter) of a closedprotrusion 22 refers to a lower width 56 as measured between twofurthermost separated points on the upper surface 14 of the base support15 closest to the rising side walls on either side of a closedprotrusion 22, and an upper width 58 as measured between two furthermostseparated points on the top surface 24 of a closed protrusion 22. Thewidth (or diameter) of an open protrusion 18 refers to an interior upperwidth 60 as measured between two furthermost separated points at the topof the cavity 20 interior wall of the open protrusion 18, and aninterior lower width as measured between two furthermost separatedpoints at the bottom of the cavity 20 interior wall of the openprotrusion 18. Non-limiting suitable examples of any of the foregoingwidths for an open protrusion 18, closed protrusion 22, or both include:about 0.5 inch to about 7 inches, about 0.5 inch to about 6 inches,about 0.5 inch to about 5 inches, about 0.5 inch to about 4 inches,about 0.5 inch to about 3 inches, about 0.5 inch to about 2 inches,about 1 inch to about 7 inches, about 1 inch to about 6 inches, about 1inch to about 5 inches, about 1 inch to about 4 inches, about 1 inch toabout 3 inches, and about 1 inch to about 2 inches. Any width of aclosed protrusion 22 may be greater than, less than, or the same as anywidth of an open protrusion 18. In some embodiments, the lower width 56of a closed protrusion 22 is greater than the interior upper width 60 ofan open protrusion 18.

In some embodiments, a width of an open or closed protrusion 18, 22 maybe selected so as to achieve a desired temperature range of the beddingproduct 10 while in use, whereby greater widths may allow for a greaterdegree of heat-dissipation and/or support. A single bedding product 10may include open 18 and closed 22 protrusions of varying widths in orderto provide the bedding product 10 with multiple, varied thermal andsupport patterns in.

The shape of a protrusion may vary. In some embodiments, the outerperimeter of a protrusion (e.g., the overall shape of the cavity 20 ofan open protrusion 18 and/or the overall shape of a closed protrusion22), as viewed from a top view looking down at the bedding product 10beneath, may have a shape that is round, square, oval, triangle,rectangular, polygonal, hexagonal, star shaped, spiral, or the like.Other shapes are possible. The shape may be symmetrical or asymmetrical.The protrusions 18, 22 of a particular embodiment may be all of the sameshape, or may be different shapes—e.g., some square and some round. Insome embodiments, some or all of the protrusions 18, 22 in a first zonemay have the same shape, and some or all of the protrusions 18, 22 in asecond zone may have a different shape.

One or more dimension of each open protrusion 18 may be the samethroughout the bedding product 10—e.g., all open protrusions 18 havingthe same depth 54 of the cavity 20. Alternatively, one or more dimensionof each open protrusion 18 may vary throughout the bedding product10—e.g., the depth 54 of the cavity 20 of open protrusions 18 in a firstzone may be greater than the depth 54 of the cavity 20 of openprotrusions 18 in a second zone. Similarly, one or more dimension ofeach closed protrusion 22 may be the same throughout the bedding product10—e.g., all closed protrusions 22 having the same height 52.Alternatively, one or more dimension of each closed protrusion 22 mayvary throughout the bedding product 10—e.g., the height 52 of closedprotrusions 22 in a first zone may be greater than the height 52 ofclosed protrusions 22 in a second zone.

An open protrusion 18 includes a rim 19 at the top of an inner wall 23,which defines the cavity 20. The thickness 66 of rim 19 may vary—e.g.,about 0.25 inch to about 2 inches, about 0.25 inch to about 1.5 inches,about 0.25 inch to about 1 inch, or 0.25 inch to about 0.75 inch. Insome embodiments, open protrusions 18 having a thicker rim 66 providemore support.

The shape of a cavity 20 may vary. In some embodiments, the overallinterior shape of the cavity 20 is rounded or angular. In someembodiments, at least a portion (e.g., at least 0.25 inch, at least 0.5inch, or at least 1 inch) of the bottom interior surface of the cavity20 is flat, convex, or concave. In some embodiments, at least a portion(e.g., at least 0.25 inch, at least 0.5 inch, or at least 1 inch) of theheight of an inner wall 23 of the cavity 20 is straight. In someembodiments, at least a portion (e.g., at least 0.25 inch) of an innerwall 23 of the cavity 20 is rounded.

The depth 54 of the cavity 20, as measured from the bottom (i.e.,lowermost interior point) of the cavity 20 to the top of the rim 19, mayvary. Non-limiting examples of suitable depths 54 of cavity 20 include:at least 0.5 inch, at least 1 inch, at least 1.5 inches, at least 2inches, at least 2.5 inches, about 0.5 inch to about 5 inches, about 0.5inch to about 4 inches, about 0.5 inch to about 3 inches, about 0.5 inchto about 2 inches, or about 0.5 inch to about 1.0 inch.

As shown in FIG. 1D, channels 32 are provided between protrusions 18, 22of the bedding product 10. In some aspects, the depth of a channel 32 isthe same as the height 52 of an adjacent protrusion. In someembodiments, as depicted in FIG. 1D, the depth of a cavity 20 may beless than the depth of an adjacent channel 32. In other embodiments, thedepth 54 of a cavity 20 may be greater than or the same as the depth ofan adjacent channel 32. The lower width 64 of a channel 32 is defined asthe widest distance along the upper surface 14 of the base support 15between two adjacent protrusions 18, 22. The upper width 62 of a channel32 is defined as the widest distance between the tops 24, 26 of twoadjacent protrusions 18, 22. In some embodiments, the upper width 62 andlower width 64 of the channel 32 may be the same. In some embodiments,the upper width 62 may be larger than the lower width 64 of the channel32. In some embodiments, the upper width 62 may be smaller than thelower width 64 of the channel 32. In some embodiments, regions or zonesof a bedding product 10 having channels 32 with a larger width willprovide more air flow and heat-dissipation in those regions or zones. Asingle bedding product 10 may have channels 32 of varying lower widths64 in order to provide multiple, varied thermal patterns inbody-contacting zones of the bedding product 10.

The channels 32 can be formed, for example, by molding, cutting, diggingtrenches into, routing, using surface modification techniques on,convoluting, compression cutting or otherwise working the support layer.The channels 32 may be formed at the same time that the protrusions 18,22 are formed.

Foams

One or more layers of the bedding product 10 may comprise foam. In someembodiments, the first layer 12 of the bedding product 10 comprisesfoam. In some embodiments, the first layer 12 is made from a materialconsisting entirely of foam.

As used herein, “foam” refers to any type of air filled matrixstructures including, without limitation, conventional foam, highresilience foam, latex foam rubber, viscoelastic foam, polyurethanefoam, memory foam, slow recovery foam, ground foam, latex foam, reflexfoam, continuous foam, hyper-soft resilient foam, hyper-soft highairflow viscoelastic foam, or combinations thereof. In some embodiments,the foam may be hyper-soft high airflow viscoelastic foam. In otherembodiments, the foam may be viscoelastic polyurethane foam or memoryfoam. See U.S. 2005/0278852. These examples are provided forillustrative purposes only; the foam can have other compositions inother embodiments. Memory foam is generally temperature-sensitive, soenvironmental temperatures or a user's body heat may affect how the foamfeels. For example, memory foam responds to a user's body heat and moldsaround the user; thus, the foam may aid in relieving pressure points,preventing pressure sores, improving circulation and the like. Higherdensity memory foam may mold to a warm human body in a few minutes.

In some embodiments, the foam may be polyurethane foam made from aformulation comprising an isocyanate, a surfactant, and a polyol blendcomprising a vegetable oil polyol. See U.S. Pat. No. 7,700,661. In someembodiments, the foam may be polyurethane foam made from a formulationcomprising a polyol blend comprising a petrochemical polyol and avegetable oil polyol, and an isocyanate blend comprising a 2, 4 toluenediisocyanate (TDI) isomer and a 2, 6 TDI isomer, wherein the ratio ofpetrochemical polyol to vegetable oil polyol in the polyol blend isabout equal to the ratio of the 2, 4 TDI isomer to the 2, 6 TDI isomerin the isocyanate blend. See U.S. Pat. No. 7,700,661. In someembodiments, the foam may further include one or more additives such as,without limitation, activators, stabilizers, amines, colorants, dyes,pigments, fragrances, chain-extending agents, surface-active agents(i.e., surfactants), fillers, and combinations thereof.

Methods of Manufacturing

Methods for fabricating a heat-dissipating bedding product 10 withheat-sink zones 4 and support zones 2 are next described. In oneembodiment, the method includes (a) providing a support layer comprisingsubstrate material; (b) forming a plurality of open protrusions 18 intothe support layer using Surface Modification Technology (SMT), the openprotrusions 18 having a cavity 20 formed in the top surface 26; (c)forming a plurality of closed protrusions 22 having a continuous topsurface 24. In some embodiments, the open 18 and closed 22 protrusionsare arranged into zones. Zones comprising open protrusions 18 will actas a heat-sink 4 to improve heat-dissipation. Zones comprising closedprotrusions 22 will come in contact with, and provide support to, one ormore parts of the body selected from the group consisting of thehead/neck 40, shoulders 42, waist 44, hips 46, and legs/feet 48, and anycombination thereof.

In some embodiments, the substrate material is conventional foam, highresilience foam, latex foam rubber, viscoelastic foam, polyurethanefoam, memory foam, slow recovery foam, ground foam, latex foam, reflexfoam, continuous foam, hyper-soft resilient foam, hyper-soft highairflow viscoelastic foam, or a combination thereof.

In some embodiments, the open 18 and closed 22 protrusions may be formedby molding the foam substrate material into protrusions 18, 22 that areraised above the first layer 12, and in the case of the open protrusions18, may comprise a cavity 20 in the top surface 26. In alternativeembodiments, the open 18 and closed 22 protrusions may be formedseparately from the first layer 12, and can be glued or otherwiseaffixed to the first layer 12.

In some embodiments, the protrusions are formed using SMT of the foamsubstrate, including compression cutting or convoluting. See U.S. Pat.No. 5,534,208. A raised pattern of foam may be formed as heat-sink 4 andsupport 2 groupings using convoluting and/or compression cutting. Theconvoluting process may include feeding a slab of foam (such as flexiblepolyurethane, bonded/combined or memory foam) through a convoluter,which includes a set of patterned rollers and a blade that cuts the foamto produce two identical parts. The convoluter draws the foam across itsblade in a generally horizontal direction to form two surfaces at thelocation where the foam splits. The studs of the patterned rollers applypressure to the foam as the blade splits the compressed foam. Therollers are each set at a constant throughput speed (such as up to65′/min, or another speed that is appropriate for the material) and haveidentical spacing from the blade. The closer the rollers are to theblade, the deeper the valley of the patterns in the foam. The rollerscan be removed and replaced with stud patterns that will produce thedesired patterns and spacing in the foam.

Alternatively, in a compression cutting process, a sheet of foam havingan upper and lower surface, is compressed by a pressure componentagainst a dye surface that bears a desired pattern. The spacing betweenthe pressure component and die surface is such as to force of the uppersurface of the foam slab against the die surface with sufficient forceto extrude foam portions into the depressions, while portions of thefoam surface underlying the flat end surfaces are compressed against thecompression component. Just beyond the point of compression between thedie surface and the compression component, the slab advances againstcutting blade which is positioned between the die surface and thecompression component to slice though the foam slab and cut away thoseportions of the foam extruding into the depressions while sparing thefoam portions compressed by the die surface and the compressioncomponent. The foam slab is cut in this fashion to produce aheat-dissipating bedding product 10 with a three-dimensionally shapedsurface and a scrap sheet, which consists of the foam material extrudedinto the slots and cut away from the slab. The pattern will create thedesired open 18 and/or closed 22 protrusions in the heat-sink 4 orsupport 2 zones of the foam, as described above. The material runningthrough the equipment will be pressed onto the pattern, as a blade cutsout the compressed sections. This will create a bedding product 10 withthe open 18 and/or closed 22 protrusions of the desired pattern. In someembodiments the die surface and pressure components are on cylindricalrollers.

In general, the end result of both operations is a patterned foam sheetwith open 18 and/or closed 22 protrusion areas, as shown by way ofexample in FIGS. 1A-1D. Patterns may vary in size and shape to achieveoptimal heat-dissipation and support. The above manufacturing operationsare described for illustrative purposes sonly; the protrusions 18, 22can be formed by other operations.

Although the present inventive concepts have been described inconsiderable detail with reference to certain preferred embodimentsthereof, other versions are possible. Therefore, the spirit and scope ofthe invention should not be limited to the description and the variousspecific examples described within this specification. All referencescited and/or discussed in this specification are hereby incorporated byreference in their entireties.

What is claimed is:
 1. A bedding product comprising a first layer offoam, wherein the first layer comprises: a base support having an uppersurface and a lower surface; a plurality of open protrusions positionedon the upper surface of the base support, each open protrusioncomprising a cavity formed therein, wherein the cavity has a depth of atleast 0.5 inch; and a plurality of closed protrusions positioned on theupper surface of the base support.
 2. The bedding product of claim 1,wherein the cavity of the open protrusion has a depth of at least 1inch.
 3. The bedding product of claim 1, wherein the open and closedprotrusions are arranged in a pattern along the upper surface of thebase support.
 4. The bedding product of claim 1, wherein: the openprotrusions are arranged in one or more heat-sink groupings; the closedprotrusions are arranged in one or more support groupings, and theheat-sink groupings and the support groupings are arranged in analternating pattern.
 5. The bedding product of claim 4, wherein at leastone of the heat-sink grouping comprises five or more open protrusions,and at least one of the support grouping comprises five or more closedprotrusions.
 6. The bedding product of claim 4, wherein at least one ofthe support groupings forms a support zone positioned to correspond to apredetermined portion of a user's body and to provide resistance thatpromotes at least one effect on the user's body selected from bloodcirculation, recovery, and facilitation of slow wave sleep.
 7. Thebedding product of claim 1, wherein the first layer defines an uppermostfoam layer of the bedding product.
 8. The bedding product of claim 1,wherein the bedding product comprises a plurality of layers and thefirst layer is the uppermost support layer.
 9. The bedding product ofclaim 1, wherein top surfaces of the open and closed protrusions definean uppermost foam surface of the bedding product.
 10. The beddingproduct of claim 1, wherein at least one closed protrusion has acontinuous top surface.
 11. The bedding product of claim 1, wherein atleast one closed protrusion is solid.
 12. The bedding product of claim1, wherein a top surface of at least one closed protrusion is outwardlyrounded.
 13. The bedding product of claim 1, further comprising a secondlayer directly attached to the lower surface of the base support. 14.The bedding product of claim 13, wherein the second layer is the same asthe first layer.
 15. The bedding product of claim 1, wherein the basesupport has a thickness of about 0.25 inches to about 3 inches.
 16. Thebedding product of claim 1, wherein the bedding product is a mattress.17. The bedding product of claim 1, wherein the bedding product is amattress topper.
 18. The bedding product of claim 1, wherein the beddingproduct provides greater heat-dissipation than a bedding productcomprising a base support without protrusions.
 19. The bedding productof claim 1, wherein the bedding product provides greater air flow than abedding product comprising a base support without protrusions.